Optimizing Powered Haulage Investment

in Surface Coal Applications

Jonathan W. Baucom – Application Engineer
Optimizing Powered Haulage Investment

All mines require efficient equipment to move material in a cost and time
effective manner. As this pertains to all mines the focus today will be
with surface coal operations and the following key points:
1. Horsepower - The effect it has with fuel consumption and requirements
for coal haul profiles vs. other applications
2. Gear Ratio - Analyze the effect gear ratio has on performance and how
this should be interpreted for achieving best operation in the field
3. Cost per Tonne – Discuss in regards to what the driving factors are and
how the current coal market allows for greater mine flexibility
Mine Operating Costs
 What percentage of mining operation costs are
attributed to open pit mining equipment?

 Generalized mine operation costs

Powered Haulage Operating Costs
 What are the main drivers of operating costs?

 Fuel consumption is always the primary cost with haulage and loading fleets
Horsepower & Fuel Consumption
 Fuel consumption is directly proportional to horsepower
20V4000 640
100% Load Factor Fuel Consumption (L/hr)

617

16V4000 QSK 78

522 547

490
QSK 60
455

Rated Engine Output (hp)

 Only four major engine types for >240tonne electric drive mining trucks
Haul Profile Definition

 What defines a haul profile? 350m @ 0%

200m @ 10%
4000m @ 0%

Typical Coal Haul

1000m @ 10%

 Segment Length
200m @ 0%

 Segment Grade
 Rolling Resistance
200m @ 0%
 Speed Limits
2500m @ -10%
Typical Downhill Loaded Haul
350m @ 0%
500m @ 10%
1600m @ 0%
Gear Ratio Effects

 37.33:1 ratio
 Greater top end
300k lb-f vs. 350k lb-f speed – 64kph
 43.7:1 ratio
 Greater low-end
“breakout” torque
 Lower top end
speed – 54kph
54kph (34mph) vs.
64kph (40mph)

0 5 10 15 20 25 30 35 40 45
mph Speed
Cost per Ton Drivers

 Payload
 The most effective way at lowering a cost per tonne is to increase
payload
 More material hauled = more $$
 Horsepower
 Cycle Times
 Fuel consumption
 GVW
 Plays important role in cycle times, fuel consumption and is
influenced by horsepower
 This study is not a comparison of any two OEM’s equipment, thus
GVW has been excluded
Old Belief still holds true?

 To Recap:
1. Primary mining operating cost is fuel
2. Higher horsepower equals higher potential fuel consumption
3. Coal haul profiles are generally flat and long
4. Low gear ratio has higher top end speed than high gear ratio
5. High payload is essential to low cost per ton

 So it makes sense that to optimize the productivity and

profitability of a surface coal mine, the investment in powered
haulage should be one with high payload, low gear ratio, low
horsepower…..

……………yet is this still the case today???

Revisit Horsepower
 HP and fuel implications
20V4000

16V4000
QSK 78

QSK 60 .175
L/hp

 As engine ratings approach and exceed 3000hp fuel efficiency

continues to improve
Revisit Horsepower
 Speed on grade is a direct function of Horsepower and GVW

+350hp = 2kph!

 Every 100hp ≈ 0.41 kph, or 0.25 mph on 8% and 10% grade

 Based on T 282 B, 592mt GVW 43.7 gear ratio
Revisit Gear Ratio

Thousands T 282 B - 43.7:1 Propulsion Curve Hp Comparison

160
Constant Torque until “Separation Point”
140 Once beyond SP hp variance then affects propulsion curve
120
2700hp
Rimpull (kg)

100
3000hp
3000hp
80 3650hp
3650hp
Propulsion Separation Point 5.4 kph
60 Propulsion
3650 37.3:1Separation Point 5.4 kph

40
20
0
0.0 10.0 20.0 30.0 40.0 50.0 60.0
Speed (kph)
 Low end torque needed for high RR at face and dump sites
 43.7:1 better suited for soft underfoot conditions, less often under loaded intentionally due to
struggling to pull away from the face when fully loaded (greater TPH!!!)
 World wide tire shortage causing many mines to restrict speeds and TKPH, thus taking away
advantage of lower gear ratio’s top end capability
 43.7:1 more efficient than 37:33 on grade thus creates less heat and requires less cooling
Coal Market Trends

+95%
+40%

+7%

*Courtesy of Energy Information Administration

 Coal demand has caused prices to outpace supply both domestically and
internationally over the past five years
 2007 was second highest year of U.S. production, only to 2006 production
Haul Simulation Study
 75 coal haul profiles from three separate operations were simulated with increased RR at
the face as seen at each operation
 Typical mine speed limit of 50kph (31mph)

Fuel Consumption
Tonne per Hour

 37.3 to illustrate old beliefs and provide baseline of new concepts

 3650hp with 43.7 gear ratio - most productive with only marginal increase in fuel burn
Production is King
 Production is always paramount at any mining operation
 Coal prices are continually on the rise
*Based on
2007 Domestic
Coal Prices
Tonne per Litre

Revenue per Hour

>9.0% $/hr

 Tonne per Litre within 1-2%, yet the 3650hp with higher gear ratio has a 9% greater
revenue/profitability
 Cost per tonne is significant but production holds greater weight
Conclusion
 Proper horsepower, gear ratio and payload matching for mining applications still
holds true today
 The world-wide coal market is spawning new concepts in the industry; deeper
pits for coal, higher hp fleets, ultra class trucks
 Coal is the dominant energy source for at least the next two decades
 The haul simulation study performed was on actual haul profiles, not generic
 To fully optimize production and profitability for a coal mine the following key
components of a powered haulage fleet must be taken into account:
1. High Payload – Ultra Class payload for maximum production
capability
2. High Horsepower – Technologically advanced, efficient engines for
greater speed on grade as coal mines expand from surging prices
3. High Gear Ratio – Need low end torque for soft conditions,
sufficient cooling for deeper pits, and operation top end speed not
an issue due to speed limits and tire preservation
Thank you…